Electrical connector and method of electrically coupling first and second electrical terminals of first and second battery cells to one another

ABSTRACT

An electrical connector includes a first terminal assembly having a first pin assembly with a first plurality of pins and a second plurality of pins is provided. The electrical connector includes a first end cap attached to the first terminal assembly to urge a first electrical terminal against the first plurality of pins such that the first plurality of pins extend through and contact the first electrical terminal. The electrical connector includes a second terminal assembly having a first pin assembly with a first plurality of female pins and a second plurality of pins. The electrical connector includes a second end cap attached to the second terminal assembly to urge a second electrical terminal against the second plurality of pins of the first pin assembly of the second terminal assembly such that the second plurality of pins of the first pin assembly of the second terminal assembly extend through and contact the second electrical terminal.

BACKGROUND

The inventor herein has recognized a need for an improved electricalconnector and an improved method of electrically coupling first andsecond electrical terminals of first and second battery cells,respectively, to one another.

SUMMARY

An electrical connector in accordance with an exemplary embodiment isprovided. The electrical connector includes a first terminal assemblyhaving a first pin assembly with a first plurality of pins and a secondplurality of pins. The first plurality of pins are electrically coupledtogether. The second plurality of pins of the first terminal assemblyare electrically coupled together. The first plurality of pins areelectrically coupled to the second plurality of pins of the firstterminal assembly. The electrical connector further includes a first endcap that is removably attached to the first terminal assembly to urge afirst electrical terminal against the first plurality of pins such thatthe first plurality of pins extend through and contact the firstelectrical terminal, and the first electrical terminal is held betweenthe first end cap and the first terminal assembly. The electricalconnector further includes a second terminal assembly having a first pinassembly with a first plurality of female pins and a second plurality ofpins. The first plurality of female pins are electrically coupledtogether. The second plurality of pins of the second terminal assemblyare electrically coupled together, and the first plurality of femalepins are electrically coupled to the second plurality of pins of thesecond terminal assembly. Each female pin of the first plurality offemale pins are configured to receive a respective pin of the secondplurality of pins of the first terminal assembly therein. The electricalconnector further includes a second end cap that is removably attachedto the second terminal assembly to urge a second electrical terminalagainst the second plurality of pins of the first pin assembly of thesecond terminal assembly such that the second plurality of pins of thefirst pin assembly of the second terminal assembly extend through andcontact the second electrical terminal, and the second electricalterminal is held between the second end cap and the second terminalassembly.

A method of electrically coupling first and second electrical terminalsof first and second battery cells, respectively, to one another inaccordance with another exemplary embodiment is provided. The methodincludes providing a first terminal assembly having a first pin assemblywith a first plurality of pins and a second plurality of pins. The firstplurality of pins are electrically coupled together, the secondplurality of pins of the first terminal assembly are electricallycoupled together, and the first plurality of pins are electricallycoupled to the second plurality of pins of the first terminal assembly.The method further includes providing a second terminal assembly havinga first pin assembly with a first plurality of female pins and a secondplurality of pins. The first plurality of female pins are electricallycoupled together. The second plurality of pins of the second terminalassembly are electrically coupled together, and the first plurality offemale pins are electrically coupled to the second plurality of pins ofthe second terminal assembly. The method further includes providingfirst and second end caps. The method further includes attaching thefirst end cap to the first terminal assembly to urge the firstelectrical terminal against the first plurality of pins of the first pinassembly such that the first plurality of pins of the first terminalassembly extend through and contact the first electrical terminal, andthe first electrical terminal is held between the first end cap and thefirst terminal assembly. The method further includes disposing each pinof the second plurality of pins of the first terminal assembly in arespective female pin of the first plurality of female pins of the firstpin assembly of the second terminal assembly. The method furtherincludes attaching the second end cap to the second terminal assembly tourge the second electrical terminal against the second plurality of pinsof the first pin assembly of the second terminal assembly such that thesecond plurality of pins of the first pin assembly of the secondterminal assembly extend through and contact the second electricalterminal, and the second electrical terminal is held between the secondend cap and the second terminal assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a battery cell assembly having first and secondbattery cells and an electrical connector in accordance with anexemplary embodiment;

FIG. 2 is a cross-sectional schematic of a portion of the battery cellassembly of FIG. 1;

FIG. 3 is an exploded schematic of the electrical connector of FIG. 1;

FIG. 4 is an exploded and cross-sectional schematic of the electricalconnector of FIG. 1;

FIG. 5 is another exploded and cross-sectional schematic of theelectrical connector of FIG. 1;

FIG. 6 is a cross-sectional schematic of the electrical connector ofFIG. 1;

FIG. 7 is another cross-sectional schematic of the electrical connectorof FIG. 1;

FIG. 8 is another cross-sectional schematic of the electrical connectorof FIG. 1;

FIG. 9 is a schematic of a first terminal assembly utilized in theelectrical connector of FIG. 1;

FIG. 10 is another schematic of the first terminal assembly of FIG. 9;

FIG. 11 is a top view of the first terminal assembly of FIG. 9;

FIG. 12 is a bottom view of the first terminal assembly of FIG. 9;

FIG. 13 is a schematic of an end portion of the first terminal assemblyof FIG. 9;

FIG. 14 is a schematic of another end portion of the first terminalassembly of FIG. 9;

FIG. 15 is a schematic of portions of a first terminal assembly and asecond terminal assembly utilized in the electrical connector of FIG. 1;

FIG. 16 is an enlarged schematic of portions of the first terminalassembly and the second terminal assembly of FIG. 15 having an uncoupledoperational position;

FIG. 17 is another enlarged schematic of portions of the first terminalassembly and the second terminal assembly of FIG. 15 having a coupledoperational position;

FIG. 18 is a schematic of a first end cap utilized in the battery cellassembly of FIG. 1;

FIG. 19 is another schematic of the first end cap of FIG. 18;

FIG. 20 is a schematic of a second terminal assembly utilized in theelectrical connector of FIG. 1;

FIG. 21 is another schematic of the second terminal assembly of FIG. 20;

FIG. 22 is a top view of the second terminal assembly of FIG. 20;

FIG. 23 is a bottom view of the second terminal assembly of FIG. 20;

FIG. 24 is a schematic of first and second pin assemblies utilized inthe second terminal assembly of FIG. 20;

FIG. 25 is a side view of the first pin assembly of FIG. 24;

FIG. 26 is a schematic of an end portion of the second terminal assemblyof FIG. 20;

FIG. 27 is a schematic of another end portion of the second terminalassembly of FIG. 20;

FIG. 28 is a schematic of a second end cap utilized in the electricalconnector of FIG. 1; and

FIG. 29 is a flowchart of a method for coupling first and secondelectrical terminals of first and second battery cells, respectively, toone another, in accordance with another exemplary embodiment.

DETAILED DESCRIPTION

Referring to FIGS. 1-8, a battery cell assembly 10 having battery cells20, 22 and an electrical connector 30 in accordance with an exemplaryembodiment is provided. The electrical connector 30 physically andelectrically couples the battery cells 20, 22 to one another as will beexplained in greater detail below.

The battery cell 20 includes a body portion 50 and electrical terminals52, 54. The electrical terminals 52, 54 extend from first and secondends, respectively of the body portion 50. The battery cell 20 generatesan operational voltage between the electrical terminals 52, 54. In anexemplary embodiment, the battery cell 20 is a lithium-ion pouch-typebattery cell. Of course, in an alternative embodiment, other types ofbattery cells could be utilized.

The battery cell 22 includes a body portion 60 and electrical terminals62, 64. The electrical terminals 62, 64 extend from first and secondends, respectively of the body portion 60. The battery cell 22 generatesan operational voltage between the electrical terminals 62, 64. In anexemplary embodiment, the battery cell 22 is a lithium-ion pouch-typebattery cell. Of course, in an alternative embodiment, other types ofbattery cells could be utilized.

Referring to FIGS. 2 and 3, the electrical connector 30 is provided toelectrically and physically couple together the electrical terminals 52,62 of the battery cells 20, 22, respectively. The electrical connector30 includes a first terminal assembly 70, a first end cap 72, a secondterminal assembly 74, and a second end cap 76.

Referring to FIGS. 3 and 9-14, the first terminal assembly 70 isconfigured to be removably coupled to the second terminal assembly 74and the first end cap 72. The first terminal assembly 70 includes ahousing 100, a first pin assembly 102, and a second pin assembly 104.

The housing 100 includes a body portion 114 and coupling tabs 116, 118disposed on opposite ends of the body portion 114. The body portion 114includes first, second, third, fourth, fifth, sixth sides 120, 122, 124,126, 128, 130. The first and second sides 120, 122 are disposedsubstantially parallel to one another. Further, the third and fourthsides 124, 126 are disposed substantially parallel to one another andperpendicular to the first and second sides 120, 122. Still further, thefifth and sixth sides 128, 130 are disposed substantially parallel toone another and perpendicular to the first and second sides 120, 122.The body portion 114 includes a cut-out region 140 extending from thesecond side 122 into the body portion 114. In an exemplary embodiment,the housing 100 is constructed of plastic.

Referring to FIGS. 3, 9-12 and 15, the first pin assembly 102 ispartially disposed in the body portion 114 and includes a firstplurality of pins 160, a central member 162, and a second plurality ofpins 164. The first pin assembly 102 is provided to puncture theelectrical terminal 52 such that the first plurality of pins 160 extendthrough and are physically and electrically coupled to the electricalterminal 52. The first pin assembly 122 is further provided toelectrically couple the first terminal assembly 70 to the secondterminal assembly 74. The first pin assembly 102 is constructed of anelectrically conductive material. For example, in an exemplaryembodiment, the first pin assembly 102 can be constructed of at leastone of copper, aluminum, steel, and tin.

The first plurality of pins 160 are coupled to and extend from a firstside of the central member 162 in a first direction away from thecentral member 162. The first plurality of pins 160 are electricallycoupled together. Each pin of the first plurality of pins 160 isdisposed a predetermined longitudinal distance from an adjacent pin ofthe first plurality of pins 160. The longitudinal width of each pin ofthe first plurality of pins 160 is greater than a longitudinal width ofeach pin of the second plurality of pins 164. Further, the firstplurality of pins 160 extend outwardly from the first side 120 (shown inFIG. 9) of the housing 100.

The second plurality of pins 164 are coupled to and extend from a secondside of the central member 162 in a second direction away from thecentral member 162. The second plurality of pins 164 are electricallycoupled together. Further, second plurality of pins 164 are electricallycoupled to the first plurality of pins 160. Each pin of the secondplurality of pins 164 is disposed a predetermined longitudinal distancefrom an adjacent pin of the second plurality of pins 162. The seconddirection is in an opposite direction relative to the first direction.The second plurality of pins 164 are disposed within the cut-out region140 (shown in FIG. 10) of the housing 100. Further, the central member162 is embedded within the body portion 114.

The second pin assembly 104 is partially disposed in the body portion114 and is disposed a predetermined distance from the first pin assembly102 and extends substantially parallel to the first pin assembly 102.The second pin assembly 104 includes a first plurality of pins 180, acentral member 182, a second plurality of pins 184, and a voltagesensing extension portion 186. The second pin assembly 104 is providedto puncture the electrical terminal 52 such that the first plurality ofpins 180 extend through and are physically and electrically coupled tothe electrical terminal 52. The second pin assembly 104 is furtherprovided to electrically couple the first terminal assembly 70 to thesecond terminal assembly 74. The second pin assembly 104 is constructedof an electrically conductive material. For example, in an exemplaryembodiment, the second pin assembly 104 can be constructed of at leastone of copper, aluminum, steel, and tin.

The first plurality of pins 180 are coupled to and extend from a firstside of the central member 182 in a first direction away from thecentral member 182. The first plurality of pins 180 are electricallycoupled together. Each pin of the first plurality of pins 180 isdisposed a predetermined longitudinal distance from an adjacent pin ofthe first plurality of pins 180. The longitudinal width of each pin ofthe first plurality of pins 180 is greater than a longitudinal width ofeach pin of the second plurality of pins 184. Further, the firstplurality of pins 180 extend outwardly from the first side 120 (shown inFIG. 9) of the housing 100.

The second plurality of pins 184 are coupled to and extend from a secondside of the central member 182 in the second direction away from thecentral member 182. The second plurality of pins 184 are electricallycoupled together. Further, the second plurality of pins 184 areelectrically coupled to the first plurality of pins 180. Each pin of thesecond plurality of pins 184 is disposed a predetermined longitudinaldistance from an adjacent pin of the second plurality of pins 182. Thesecond plurality of pins 184 are disposed within the cut-out region 140(shown in FIG. 10) of the housing 100. Further, the central member 182is embedded within the body portion 114.

The voltage sensing extension portion 186 is integrally coupled to thecentral member 182 and extends outwardly from the third side 124 (shownin FIG. 10) of the body portion 114. The voltage sensing extensionportion 186 has an aperture 137 extending therethrough. The voltagesensing extension portion 186 is advantageously provided to allow acomputer to monitor a voltage and a temperature of the battery cells 20,22.

Referring to FIGS. 3, 18 and 19, the first end cap 72 is removablyattached to the first terminal assembly 70 to urge the electricalterminal 52 against the first plurality of pins 160 such that the firstplurality of pins 160 extend through and contact the electrical terminal52, and the electrical terminal 52 is held between the first end cap 72and the first terminal assembly 70. The first end cap 72 includes an endcap portion 200 and first and second finger portions 202, 204. The firstand second finger portions 202, 204 are coupled to first and secondends, respectively, of the end cap portion 200 and extend outwardly fromthe end cap portion 200 substantially perpendicular to the end capportion 200. The first and second finger portions 202, 204 haveapertures 212, 214, respectively, extending therethrough. The apertures212, 214 are adapted to receive the coupling tabs 116, 118 (shown inFIGS. 9 and 10), respectively, of the housing 100 of the first terminalassembly 70. In an exemplary embodiment, the first end cap 72 isconstructed of plastic.

Referring to FIGS. 3 and 20-27, the second terminal assembly 74 isconfigured to be removably coupled to the first terminal assembly 70 andthe second end cap 72. The second terminal assembly 74 includes ahousing 300, a first pin assembly 302, and a second pin assembly 304.

The housing 300 includes a body portion 314 and coupling tabs 316, 318disposed on opposite ends of the body portion 314. The body portion 314includes first, second, third, fourth, fifth, sixth sides 320, 322, 324,326, 328, 330. The first and second sides 320, 322 are disposedsubstantially parallel to one another. Further, the third and fourthsides 324, 326 are disposed substantially parallel to one another andperpendicular to the first and second sides 320, 322. The body portion314 includes a first plurality of apertures 340 extending therethroughfrom the first side 320 to the second side 322. The body portion 314further includes a second plurality of apertures 342 extendingtherethrough from the first side 320 to the second side 322. In anexemplary embodiment, the housing 300 is constructed of plastic.

Referring to FIGS. 3, 15, 24 and 25, the first pin assembly 302 ispartially disposed in the body portion 314 and includes a firstplurality of female pins 360, a central member 362, and a secondplurality of pins 364. The first pin assembly 302 is provided topuncture the electrical terminal 62 such that the second plurality ofpins 364 extend through and are physically and electrically coupled tothe electrical terminal 62. The first pin assembly 302 is furtherprovided to electrically couple the second terminal assembly 74 to thefirst terminal assembly 70. The first pin assembly 302 is constructed ofan electrically conductive material. For example, in an exemplaryembodiment, the first pin assembly 302 can be constructed of at leastone of copper, aluminum, steel, and tin.

Referring to FIGS. 15, 20 and 24, the first plurality of female pins 360are configured to receive the second plurality of pins 164 of the firstpin assembly 102 therein. The first plurality of female pins 360 arecoupled to and extend from a first side of the central member 362 in afirst direction away from the central member 362. The first plurality offemale pins 360 are electrically coupled together. Each pin of the firstplurality of female pins 360 is disposed a predetermined longitudinaldistance from an adjacent pin of the first plurality of female pins 360.The longitudinal width of each pin of the first plurality of female pins360 is less than a longitudinal width of each pin of the secondplurality of pins 364. Further, each female pin of the first pluralityof female pins 360 are disposed in a respective aperture of the firstplurality of apertures 340 (shown in FIG. 20) in the body portion 314.In an exemplary embodiment, each female pin of the first plurality offemale pins 360 has a portion 366 (shown in FIG. 16) having a smallerdiameter proximate to the central member 362 then a remaining portion368 of each respective female pin distal from the central member 362.The portion 366 of each female pin of the first plurality of female pins360 having the smaller diameter can be used as an overcurrent interruptdevice that transitions from a closed electrical state to an openelectrical state if the electrical current flowing through therespective portion 366 of each female pin of the first plurality offemale pins 360 is greater than the threshold current level for apredetermined amount of time.

The second plurality of pins 364 are coupled to and extend from a secondside of the central member 362 in a second direction away from thecentral member 362. The second plurality of pins 364 are electricallycoupled together. Further, the second plurality of pins 364 areelectrically coupled to the first plurality of pins 360. Each pin of thesecond plurality of pins 364 is disposed a predetermined longitudinaldistance from an adjacent pin of the second plurality of pins 362.Further, the central member 362 is embedded within the body portion 314.

The second pin assembly 304 is partially disposed in the body portion314 and is disposed a predetermined distance from the first pin assembly302 and extends substantially parallel to the first pin assembly 302.The second pin assembly 304 includes a first plurality of female pins380, a central member 382, and a second plurality of pins 384. Thesecond pin assembly 304 is provided to puncture the electrical terminal62 such that the second plurality of pins 384 extend through and arephysically and electrically coupled to the electrical terminal 62. Thesecond pin assembly 304 is further provided to electrically couple thesecond terminal assembly 74 to the first terminal assembly 70. Thesecond pin assembly 304 is constructed of an electrically conductivematerial. For example, in an exemplary embodiment, the second pinassembly 304 can be constructed of at least one of copper, aluminum,steel, and tin.

The first plurality of female pins 380 are coupled to and extend from afirst side of the central member 382 in a first direction away from thecentral member 382. The first plurality of female pins 380 areelectrically coupled together. Each pin of the first plurality of femalepins 380 is disposed a predetermined longitudinal distance from anadjacent pin of the first plurality of female pins 380. The longitudinalwidth of each pin of the first plurality of female pins 380 is less thana longitudinal width of each pin of the second plurality of pins 384.Further, the first plurality of pins 380 extend outwardly from the firstside 320 (shown in FIG. 20) of the housing 100. In an exemplaryembodiment, each female pin of the first plurality of female pins 380has a portion 386 (shown in FIG. 16) having a smaller diameter proximateto the central member 382 then a remaining portion 388 of eachrespective female pin distal from the central member 382. The portion386 of each female pin of the first plurality of female pins 380 havingthe smaller diameter can be used as an overcurrent interrupt device thattransitions from a closed electrical state to an open electrical stateif the electrical current flowing through the respective portion 386 ofeach female pin of the first plurality of female pins 380 is greaterthan the threshold current level for a predetermined amount of time.

The second plurality of pins 384 are coupled to and extend from a secondside of the central member 382 in the second direction away from thecentral member 382. The second plurality of pins 384 are electricallycoupled together. Further, second plurality of pins 384 are electricallycoupled to the first plurality of pins 380. Each pin of the secondplurality of pins 384 is disposed a predetermined longitudinal distancefrom an adjacent pin of the second plurality of pins 382. Further, thecentral member 382 is embedded within the body portion 314 (shown inFIG. 20).

Referring to FIGS. 3 and 28, the second end cap 76 is removably attachedto the second terminal assembly 74. The second end cap 76 is positionedto urge the electrical terminal 62 against the second plurality of pins384 and the second plurality of pins 364 such that the second pluralityof pins 384 and the second plurality pins 364 extend through and contactthe electrical terminal 62, and the electrical terminal 62 is heldbetween the second end cap 76 and the second terminal assembly 74. Thesecond end cap 76 includes an end cap portion 400 and first and secondfinger portions 402, 404. The first and second finger portions 402, 404are coupled to first and second ends, respectively, of the end capportion 400 and extend outwardly from the end cap portion 400substantially perpendicular to the end cap portion 400. The first andsecond finger portions 402, 404 have apertures 412, 414, respectively,extending therethrough. The apertures 412, 414 are adapted to receivethe coupling tabs 316, 318, respectively, of the housing 300 of thesecond terminal assembly 74. In an exemplary embodiment, the second endcap 76 is constructed of plastic.

Referring to FIGS. 3, 15 and 29, a flowchart of a method of electricallycoupling the electrical terminals 52, 62 of the battery cells 20, 22,respectively, to one another, in accordance with another exemplaryembodiment is provided.

At step 500, an operator provides the first terminal assembly 70 havingthe first pin assembly 102 with the first plurality of pins 160 and thesecond plurality of pins 164. The first plurality of pins 160 areelectrically coupled together. The second plurality of pins 164 of thefirst terminal assembly 70 are electrically coupled together, and thefirst plurality of pins 160 are electrically coupled to the secondplurality of pins 164 of the first terminal assembly 70.

At step 502, the operator provides the second terminal assembly 74having the first pin assembly 302 with the first plurality of femalepins 360 and the second plurality of pins 364. The first plurality offemale pins 360 are electrically coupled together. The second pluralityof pins 364 of the second terminal assembly 74 are electrically coupledtogether, and the first plurality of female pins 360 are electricallycoupled to the second plurality of pins 364 of the second terminalassembly 74.

At step 504, the operator provides the first and second end caps 72, 76.

At step 506, the operator attaches the first end cap 72 to the firstterminal assembly 70 to urge the first electrical terminal 52 againstthe first plurality of pins 160 of the first pin assembly 102 such thatthe first plurality of pins 160 of the first terminal assembly 70 extendthrough and contact the first electrical terminal 52, and the firstelectrical terminal 52 is held between the first end cap 72 and thefirst terminal assembly 70.

At step 508, the operator disposes each pin of the second plurality ofpins 164 of the first terminal assembly 70 in a respective female pin ofthe first plurality of female pins 360 of the first pin assembly 302 ofthe second terminal assembly 74.

At step 510, the operator attaches the second end cap 76 to the secondterminal assembly 74 to urge the second electrical terminal 54 againstthe second plurality of pins 364 of the first pin assembly 302 of thesecond terminal assembly 74 such that the second plurality of pins 364of the first pin assembly 302 of the second terminal assembly 74 extendthrough and contact the second electrical terminal 54, and the secondelectrical terminal 54 is held between the second end cap 76 and thesecond terminal assembly 74.

The electrical connector and the method of electrically coupling firstand second electrical terminals of first and second battery cells,respectively, to one another provide a substantial advantage over otherelectrical connectors and methods. In particular, the electricalconnectors utilize a first terminal assembly having a plurality of pinsthat are electrically coupled together that extend through and contact afirst electrical terminal of the first battery cell, and a secondterminal assembly having a plurality of pins that are electrical coupledtogether that extend through and contact a second electrical terminal ofthe second battery cell to electrically couple the first and secondbattery cells to one another.

While the claimed invention has been described in detail in connectionwith only a limited number of embodiments, it should be readilyunderstood that the invention is not limited to such disclosedembodiments. Rather, the claimed invention can be modified toincorporate any number of variations, alterations, substitutions orequivalent arrangements not heretofore described, but which arecommensurate with the spirit and scope of the invention. Additionally,while various embodiments of the claimed invention have been described,it is to be understood that aspects of the invention may include onlysome of the described embodiments. Accordingly, the claimed invention isnot to be seen as limited by the foregoing description.

1. An electrical connector, comprising: a first terminal assembly havinga first pin assembly with first, second, third, fourth, fifth, and sixthpins and a first central conductive member; the first, second, and thirdpins of the first pin assembly of the first terminal assembly beingcoupled to and extending in a first direction from the first centralconductive member; the fourth, fifth, and sixth pins of the first pinassembly of the first terminal assembly being coupled to and extendingin a second direction from the first central conductive member; thesecond direction being opposite to the first direction; the first,second, third, fourth, fifth, and sixth pins of the first pin assemblyof the first terminal assembly being electrically coupled together; afirst end cap being removably attached to the first terminal assembly tourge a first electrical terminal against the first, second, and thirdpins of the first pin assembly of the first terminal assembly such thatthe first, second, and third pins of the first pin assembly of the firstterminal assembly extend through and contact the first electricalterminal, and the first electrical terminal is held between the firstend cap and the first terminal assembly; a second terminal assemblyhaving a first pin assembly with first, second, and third female pins,and first, second, and third pins and a second central conductivemember; the first, second, and third female pins of the first pinassembly of the second terminal assembly being coupled to and extendingin the first direction from the second central conductive member; thefirst, second, and third pins of the first pin assembly of the secondterminal assembly being coupled to and extending in the second directionfrom the second central conductive member; the first, second, and thirdfemale pins and the first, second, and third pins of the first pinassembly of the second terminal assembly being electrically coupledtogether; the first, second, and third female pins of the first pinassembly of the second terminal assembly receiving the fourth, fifth,and sixth pins, respectively, of the first pin assembly of the firstterminal assembly therein; and a second end cap being removably attachedto the second terminal assembly to urge a second electrical terminalagainst the first, second, and third pins of the first pin assembly ofthe second terminal assembly such that the first, second, and third pinsof the first pin assembly of the second terminal assembly extend throughand contact the second electrical terminal, and the second electricalterminal is held between the second end cap and the second terminalassembly.
 2. The electrical connector of claim 1, wherein the firstterminal assembly further having a first housing with a first side and asecond side, the first housing having a cut-out region extending fromthe second side into the first housing.
 3. The electrical connector ofclaim 2, wherein: the first housing further includes a body portion andfirst and second coupling tabs, the first and second coupling tabs beingdisposed on first and second ends, respectively, of the body portion;and the first end cap further includes an end cap portion and first andsecond finger portions; the first and second finger portions beingcoupled to first and second ends, respectively, of the end cap portionand extending outwardly from the end cap portion substantiallyperpendicular to the end cap portion; the first and second fingerportions having first and second apertures, respectively, extendingtherethrough; the first and second apertures being adapted to receivethe first and second coupling tabs, respectively, of the first housingof the first terminal assembly.
 4. The electrical connector of claim 2,wherein: the first central conductive member being disposed within thefirst housing; and the first, second, and third pins of the first pinassembly of the first terminal assembly further extending outwardly fromthe first side of the first housing.
 5. The electrical connector ofclaim 4, wherein: the fourth, fifth and sixth pins of the first pinassembly of the first terminal assembly being disposed within thecut-out region of the first housing.
 6. The electrical connector ofclaim 5, wherein: the second terminal assembly further includes a secondhousing; the second housing having a first side and a second side andfirst, second, and third apertures extending through the second housingfrom the first side to the second side thereof; the second centralconductive member being disposed within the second housing; and thefirst, second, and third female pins of the first pin assembly of thesecond terminal assembly being disposed in the first, second, and thirdapertures, respectively, in the second housing.
 7. The electricalconnector of claim 6, wherein: the second housing of the second terminalassembly further includes a body portion and first and second couplingtabs, the first and second coupling tabs being disposed on first andsecond ends, respectively, of the body portion; and the second end capfurther includes an end cap portion and first and second fingerportions; the first and second finger portions being coupled to firstand second ends, respectively, of the end cap portion and extendingoutwardly from the end cap portion substantially perpendicular to theend cap portion; the first and second finger portions having fourth andfifth apertures, respectively, extending therethrough; the fourth andfifth apertures being adapted to receive the first and second couplingtabs, respectively of the second housing of the second terminalassembly.
 8. The electrical connector of claim 6, wherein: the first,second, and third pins of the first pin assembly of the second terminalassembly further extending outwardly from the second side of the secondhousing.
 9. The electrical connector of claim 1, wherein: the firstterminal assembly further includes a second pin assembly with first,second, third, fourth, fifth, and sixth pins, a third central conductivemember, and a voltage sensing extension portion; the first, second, andthird pins of the second pin assembly of the first terminal assemblybeing coupled to and extending in the first direction from the thirdcentral conductive member; the fourth, fifth, and sixth pins of thesecond pin assembly of the first terminal assembly being coupled to andextending in the second direction from the third central conductivemember, the voltage sensing extension portion being coupled to andextending from the third central conductive member; the first, second,third, fourth, fifth, and sixth pins of the second pin assembly of thefirst terminal assembly being electrically coupled together; the secondpin assembly of the first terminal assembly being disposed apredetermined distance from the first pin assembly of the first terminalassembly in the first housing; and the first end cap being furtheradapted to urge the first electrical terminal against the first second,and third pins of the second pin assembly of the first terminal assemblysuch that the first, second, and third pins of the second pin assemblyof the first terminal assembly extend through and contact the firstelectrical terminal.
 10. The electrical connector of claim 9, wherein:the second terminal assembly further includes a second pin assembly withfirst, second, third female pins, and first, second, and third pins, anda fourth central conductive member; the first, second, and third femalepins of the second pin assembly of the second terminal assembly beingcoupled to and extending in the first direction from the fourth centralconductive member; the first, second, and third pins of the second pinassembly of the second terminal assembly being coupled to and extendingin the second direction from the fourth central conductive member; thefirst, second, and third female pins and the first, second, and thirdpins of the second pin assembly of the second terminal assembly beingelectrically coupled together; the first, second, and third female pinsof the second pin assembly of the second terminal assembly receiving thefourth, fifth, and sixth pins, respectively, of the second pin assemblyof the first terminal assembly therein; and the second end cap beingfurther adapted to urge the first electrical terminal against the first,second, and third pins of the second pin assembly of the second terminalassembly such that the first, second, and third pins of the second pinassembly of the second terminal assembly extend through and contact thesecond electrical terminal.
 11. The electrical connector of claim 10,wherein the first pin assembly of the second terminal assembly beingdisposed a predetermined distance from the second pin assembly of thesecond terminal assembly.
 12. A method of electrically coupling firstand second electrical terminals of first and second battery cells,respectively, to one another, comprising: providing a first terminalassembly having a first pin assembly with first, second, third, fourth,fifth, and sixth pins and a first central conductive member, the first,second, and third pins of the first pin assembly of the first terminalassembly being coupled to and extending in a first direction from thefirst central conductive member; the fourth, fifth, and sixth pins ofthe first pin assembly of the first terminal assembly being coupled toand extending in a second direction from the first central conductivemember; the second direction being opposite to the first direction; thefirst, second, third, fourth, fifth, and sixth pins of the first pinassembly of the first terminal assembly being electrically coupledtogether; providing a second terminal assembly having a first pinassembly with first, second, third female pins, and first, second, andthird pins and a second central conductive member; the first, second,and third female pins of the first pin assembly of the second terminalassembly being coupled to and extending in the first direction from thesecond central conductive member; the first, second, and third pins ofthe first pin assembly of the second terminal assembly being coupled toand extending in the second direction from the second central conductivemember; the first, second, and third female pins and the first, second,and third pins of the first pin assembly of the second terminal assemblybeing electrically coupled together; the first, second, and third femalepins of the first pin assembly of the second terminal assembly receivingthe fourth, fifth, and sixth pins, respectively, of the first pinassembly of the first terminal assembly therein; attaching the first endcap to the first terminal assembly to urge the first electrical terminalagainst the first, second, and third pins of the first pin assembly ofthe first terminal assembly such that the first, second, and third pinsof the first pin assembly of the first terminal assembly extend throughand contact the first electrical terminal, and the first electricalterminal is held between the first end cap and the first terminalassembly; disposing the fourth, fifth, and sixth pins of the first pinassembly of the first terminal assembly in the first, second, and thirdfemale pins, respectively, of the first pin assembly of the secondterminal assembly; and attaching the second end cap to the secondterminal assembly to urge the second electrical terminal against thefirst, second, and third pins of the first pin assembly of the secondterminal assembly such that the first, second, and third pins of thefirst pin assembly of the second terminal assembly extend through andcontact the second electrical terminal, and the second electricalterminal is held between the second end cap and the second terminalassembly.
 13. An electrical connector, comprising: a first terminalassembly having a first pin assembly with a first plurality of pins anda second plurality of pins, the first plurality of pins beingelectrically coupled together, the second plurality of pins of the firstterminal assembly being electrically coupled together, and the firstplurality of pins being electrically coupled to the second plurality ofpins of the first terminal assembly; a first end cap being removablyattached to the first terminal assembly to urge a first electricalterminal against the first plurality of pins such that the firstplurality of pins extend through and contact the first electricalterminal, and the first electrical terminal is held between the firstend cap and the first terminal assembly; a second terminal assemblyhaving a first pin assembly with a first plurality of female pins and asecond plurality of pins; the first plurality of female pins beingelectrically coupled together, the second plurality of pins of thesecond terminal assembly being electrically coupled together, and thefirst plurality of female pins being electrically coupled to the secondplurality of pins of the second terminal assembly; each female pin ofthe first plurality of female pins having an outer wall defining aninterior aperture surrounded by the outer wall, and the interioraperture being sized and shaped to receive a respective pin of thesecond plurality of pins of the first terminal assembly therein; and asecond end cap being removably attached to the second terminal assemblyto urge a second electrical terminal against the second plurality ofpins of the first pin assembly of the second terminal assembly such thatthe second plurality of pins of the first pin assembly of the secondterminal assembly extend through and contact the second electricalterminal, and the second electrical terminal is held between the secondend cap and the second terminal assembly.